ABB Safety Instruction 3HAC027098-001 Revb en

English
Emergency safety information

Robotics products
M2004
Document ID: 3HAC 027098-001

Revision: B
© Copyright 2007-2008 ABB. All rights reserved.
The information in this manual is subject to change without notice and should not be
construed as a commitment by ABB. ABB assumes no responsibility for any errors that
may appear in this manual.
Except as may be expressly stated anywhere in this manual, nothing herein shall be
construed as any kind of guarantee or warranty by ABB for losses, damages to persons
or property, fitness for a specific purpose or the like.
In no event shall ABB be liable for incidental or consequential damages arising from
use of this manual and products described herein.
This manual and parts thereof must not be reproduced or copied without ABB's written
permission, and contents thereof must not be imparted to a third party nor be used for
any unauthorized purpose. Contravention will be prosecuted.
Additional copies of this manual may be obtained from ABB at its then current charge.
Copyright 2007-2008 ABB All rights reserved.

ABB AB
Robotics Products
SE-721 68 Västerås
Sweden
English
Table of Contents
Manual overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
1 Emergency safety information 7

1.1 Stop the system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
1.2 Fire extinguishing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
1.3 Shut down all power to the controller . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
1.4 Releasing a person trapped by the robot arm . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
1.5 Emergency release of the robot arm . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
1.6 Recover from emergency stops . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
3HAC 027098-001 Revision: B 3

4
Table of Contents
3HAC 027098-001 Revision: B

English
Manual overview
Manual overview
About this manual

This manual contains information for emergency situations in the robot system.
For any work in the robot system you must use the appropriate product, operating,
application, or reference manual.
NOTE!
This manual must always be stored together with the robot system!
This manual must always be easy to access for an operator, service engineer, or anyone using
or working with the robot system.
References
Reference Document ID
Product manual - IRC5 3HAC021313-001
Operating manual - Getting started, IRC5 and RobotStudio 3HAC027097-001
Operating manual - IRC5 with FlexPendant 3HAC16590-1
Operating manual - Trouble shooting 3HAC020738-001
Product manual for the robot
Revisions
Revision Description
- First revision.
A Polish translation added.
B IRB 360, IRB 6640, and IRB 6660 added.

6
Manual overview
3HAC 027098-001 Revision: B

English
1 Emergency safety information
1.1. Stop the system

Overview
Press any of the emergency stop buttons immediately if:
• There are any personnel in the robot working area, while the robot is working.
• The robot causes harm to personnel or mechanical equipment.
The FlexPendant emergency stop button
xx0300000449
A Emergency stop button
The controller emergency stop button

xx0600003423
A Emergency stop button, Single Cabinet Controller
Continues on next page

Continued
xx0600003424
A Emergency stop button, Dual Cabinet Controller
Other emergency stop devices

The plant designer may have placed additional emergency stop devices in convenient places.
Please consult your plant or cell documentation to find out where these are placed.
8 3HAC 027098-001 Revision: B

English
1.2. Fire extinguishing
1.2. Fire extinguishing
NOTE!
Use a CARBON DIOXIDE (CO2) extinguisher in the event of a fire in the robot system (robot
or controller)!

1.3. Shut down all power to the controller
Overview
The controller has one mains power switch on each module. To make sure that NO power is
connected to the controller, all modules’ mains switches must be turned off.
NOTE!
Your plant or cell may have additional equipment that may also need to be disconnected from
the power. Please consult your plant or cell documentation to find out where these power
switches are placed.
Shut down power to the controller
Action Info
1. Turn off the mains power switch on the If your system uses a Single Cabinet
Control Module. Controller, then only step 1 is necessary.
2. Turn off the mains power switch on all See illustration Mains power switch,
connected Drive Modules and other controller with additional cabinets on page
modules, such as spotwelding cabinets 11.
etc..
Mains power switch, Single Cabinet Controller
xx0600003428
A Mains power switch, Single Cabinet Controller

English
Continued
Mains power switch, controller with additional cabinets

Note that each connected Drive Module, or other connected modules such as a spotwelding
cabinet, has its own mains power switch. On other types of cabinets, the power switch is often
placed top left on the front of the cabinet.
xx0600003429
A Mains power switch, Control Module (Dual Cabinet Controller)

B Mains power switch, Drive Module (Dual Cabinet Controller)

1.4. Releasing a person trapped by the robot arm
1.4. Releasing a person trapped by the robot arm
Overview
If a person has been trapped by the robot arm, you must make sure that any attempt to release
the person does not further increase the risk of injury.
Releasing the robot holding brakes will make it possible to move the robot manually, but only
small robots are light enough to be moved by human force. Moving larger robots may require
using an overhead crane or similar. Make sure you have the right equipment at hand before
releasing the brakes!
WARNING!
Before releasing the brakes, make sure that the weight of the arms does not increase the
pressure on the trapped person, further increasing any injury!
How to release a trapped person

This procedure details how to release a person trapped by the robot arm.
Action Info/illustration
1. Press any of the emergency stop buttons.
2. Make sure that the trapped person will not
be more injured by the intended release
action.
3. Move the robot so that the trapped person To release the robot holding brakes, see
is released. instructions on the next page, Emergency
release of the robot arm on page 13.
4. Help the trapped person and make sure
he/she gets medical attention.
5. Make sure the robot cell is cleared so that
no one else runs the risks of being injured.

English
1.5. Emergency release of the robot arm
Overview
In an emergency situation, any of the robot axes may be released manually by pushing the
brake release buttons on the robot.
The robot arm may be moved manually on smaller robot models, but larger models may
require using an overhead crane or similar.
Increased injury
Before releasing the brakes, make sure that the weight of the arms does not increase the
pressure on the trapped person, further increasing any injury!
Releasing the robot arm

This procedure details how to release the robot arm.
The brake release unit is illustrated below. Depending on the robot model, the unit may be
placed differently, see the descriptions below.
NOTE!
If the robot is not connected to the controller, or if the controller power is shut off, you must
use an external power supply to the connector in the robot base. See External power supply
for brake release unit on page 18.
Action Info
1. The internal brake release unit is equipped with six IRB 140, IRB 1400, IRB 1410,IRB
buttons for controlling the axes brakes. The buttons 340, and IRB 360 has one release
are numbered according to the numbers of the button for all axes.
axes.
2. Make sure the robot arm is
secured with a crane or similar
before releasing the brakes!
DANGER!
When releasing the holding brakes, the robot axes
may move very quickly and sometimes in

unexpected ways! Make sure no personnel is near
the robot arm!
3. Release the holding brake on a particular robot axis
by pressing the corresponding button on the internal
brake release panel and keeping it depressed.
The brake will function again as soon as the button
is released.

Continued
Brake release unit

This illustration is a schematic overview of the brake release unit, placed in the robot frame
or base. Depending on the robot model, the placing can vary slightly. The principle with one
button per axis is however the same. Note that IRB 140, IRB 1400, IRB 1410, IRB 340, and
IRB 360, only have one button releasing all axes’ brakes at once.
The brake release unit is protected with a plate or clamp.
xx0400001255
Brake release unit, large robots

On the following large robot models the brake release unit located on the robot frame.
• IRB 6600/6650
• IRB 6620
• IRB 6640
• IRB 6650S
• IRB 660
• IRB 6660
• IRB 6400RF
• IRB 7600
The illustration below shows IRB 6600 with the brake release unit located on the frame, close
to the axis 2 motor. For IRB 6650S and IRB 660 the placing is the same.
xx0300000044

English
Continued
On IRB 6620 robots, the brake release unit is located on the frame, to the right of the axis 2
motor.
xx0600002936
On IRB 6640 robots, the brake release unit is located on the frame, close to the axis two
motor.
xx0600003402
On IRB 6660 robots, the brake release unit is located on the frame, close to the axis two
motor.
xx0700000005

Continued
On IRB 6400RF robots, the brake release unit is located close to the axis three motor.
xx0600003465
Brake release unit, medium size robots

On medium sized robot models the brake release unit is located on the robot base.
• IRB 1600
• IRB 2400
• IRB 260
• IRB 4400/4450S
xx0400001255
Brake release unit, IRB 1600
Brake release unit, small robots with one brake release button
On small robot models the brake release unit is located on the back of the robot base. Note
that there is one button releasing all six axes.
• IRB 140
• IRB 1400
• IRB 1410

English
Continued
xx0200000069
A Brake release button, IRB 140
On the IRB 340 and IRB 360, the brake release button is located on the base of the robot,
close to the center.
xx0600003437

xx0700000435

Continued
External power supply for brake release unit

If the power to the controller is switched off you must connect an external power supply to
be able to use the brake release buttons.
DANGER!
Incorrect connections, such as supplying power to the wrong pin, may cause all brakes to be
released simultaneously!
Connector R1.MP, large robots

The connector R1.MP is located in the robot base for large robots.
Supply 0 V on pin 12 and 24 V on pin 11.
Robot model Illustration

• IRB 6600/6650
• IRB 6620
• IRB 6640
• IRB 6650S
• IRB 660
• IRB 6660
• IRB 7600
xx0300000565
• IRB 6400RF
xx0600003461

English
Continued
Connector R1.MP, IRB 4400

Connect 0 V on pin B14 and 24 V on pin B16.
The connectors are located on the back of the robot base.

• IRB 4400
xx0300000200

Continued
Connector R1.MP, IRB 1400, IRB 1410, IRB 1600, IRB 2400, IRB 260
Connect 0 V on pin C10 and 24 V on pin B8.

• IRB 1400
• IRB 1410
• IRB 1600
• IRB 2400
• IRB 260
xx0400001302
Connector XP1, IRB 140

Connect 0 V on pin B14 and 24 V on pin B16.
The connectors are located on the end of the power and signal cable (which is connected to
the robot).

• IRB 140 © Copyright 2007-2008 ABB. All rights reserved.
xx020000071
A: 24 V on pin B16
B: 0 V on pin B14

English
Continued
Connector R1.MP, IRB 140

Connect 0 V on pin 13 and 24 V on pin 15 (if no power and signal cable is connected to the
robot).

• IRB 140
xx0200000072
A: 0 V on pin 13
B: 24 V on pin 15
Connector R1.MP, IRB 340 and IRB 360

Connect 0 V on pin 13 and 24 V on pin 15.

• IRB 340
2 3
1
4 5 6
7
8 9
1
10 11 12
13 14 15
xx0600003463
0 V on pin 13
24 V on pin 15

Continued

• IRB 360
xx0700000441
0 V on pin 13
24 V on pin 15

English
1.6. Recover from emergency stops
Overview
Recovering from an emergency stop is a simple but important procedure. This procedure
ensures that the robot system is not returned to production while maintaining a hazardous
condition.
Reset the latch of emergency stop buttons

All push-button style emergency stop devices have a latching feature that must be released in
order to remove the emergency stop condition of the device.
In many cases this is done by twisting the push-button as marked, but there are also devices
where you pull the button to release the latch.
Reset automatic emergency stop devices

All automatic emergency stop devices also have some kind of latching feature that must be
released. Please consult your plant or cell documentation to see how your robot system is
configured.
Recover from emergency stops
Action
1. Make sure the hazardous situation that resulted in the emergency stop condition no
longer exists.
2. Locate and reset the device or devices that gave the emergency stop condition.
3. Press the Motors On button to recover from the emergency stop condition.
The Motors On button

The Motors On button is located on the controller. On a Dual Controller the Motors On button
is located on the Control Module. If your robot system uses another type of control cabinet,
then the Motors On button may look different than the illustration below.
xx0600003430
A Motors On button


ABB Safety Instruction 3HAC027098-001 Revb en

Uploaded by

Document Information

Original Description:

Original Title

Copyright

Available Formats

Share this document

Share or Embed Document

Sharing Options

Did you find this document useful?

Is this content inappropriate?

Copyright:

Available Formats

ABB Safety Instruction 3HAC027098-001 Revb en

Uploaded by

Copyright:

Available Formats

English

Emergency safety information

Document ID: 3HAC 027098-001

© Copyright 2007-2008 ABB. All rights reserved.

Copyright 2007-2008 ABB All rights reserved.

1 Emergency safety information 7

3HAC 027098-001 Revision: B 3

3HAC 027098-001 Revision: B

About this manual

3HAC 027098-001 Revision: B 5

3HAC 027098-001 Revision: B

1 Emergency safety information

The FlexPendant emergency stop button

A Emergency stop button

The controller emergency stop button

A Emergency stop button, Single Cabinet Controller

Continues on next page

A Emergency stop button, Dual Cabinet Controller

Other emergency stop devices

© Copyright 2007-2008 ABB. All rights reserved.

8 3HAC 027098-001 Revision: B

1.2. Fire extinguishing

3HAC 027098-001 Revision: B 9

1.3. Shut down all power to the controller

Shut down power to the controller

Mains power switch, Single Cabinet Controller

© Copyright 2007-2008 ABB. All rights reserved.

A Mains power switch, Single Cabinet Controller

Continues on next page

Mains power switch, controller with additional cabinets

A Mains power switch, Control Module (Dual Cabinet Controller)

3HAC 027098-001 Revision: B 11

1.4. Releasing a person trapped by the robot arm

How to release a trapped person

© Copyright 2007-2008 ABB. All rights reserved.

12 3HAC 027098-001 Revision: B

1.5. Emergency release of the robot arm

Releasing the robot arm

may move very quickly and sometimes in

Continues on next page

Brake release unit

Brake release unit, large robots

© Copyright 2007-2008 ABB. All rights reserved.

Continues on next page

Continues on next page

Brake release unit, medium size robots

© Copyright 2007-2008 ABB. All rights reserved.

Brake release unit, IRB 1600

Continues on next page

A Brake release button, IRB 140

A Brake release button, IRB 340

A Brake release button, IRB 360

Continues on next page

External power supply for brake release unit

Connector R1.MP, large robots

Robot model Illustration

Continues on next page

Connector R1.MP, IRB 4400

Robot model Illustration

Continues on next page

Robot model Illustration

Connector XP1, IRB 140